Reducing energy consumption of mobile pumping units by determining the optimal temperature regime of high-pressure pumps
DOI:
https://doi.org/10.31471/1993-9868-2026-1(45)-195-210Keywords:
oil and gas technological transport; energy efficiency; wear; high-pressure pump; optimum tempe-rature.Abstract
The article considers the problem of increasing the energy efficiency of high-pressure pumps of mobile pumping units for hydraulic fracturing in the oil and gas industry. The results of studies of wear of friction surfaces of high-pressure pumps, intensity of change of initial dimensions and geometric shape of parts of high-pressure pumps are presented. It was established that abrasive wear is mainly caused by housings, pump bushings, precision plungers, seals, rods of crosshead mechanisms. Changes in pump operating modes, additional energy consumption, reduction of pressure and supply of high-pressure pumps due to wear of friction surfaces are analyzed. It was established that studies of energy consumption and wear of parts of high-pressure pumps of mobile pumping units for hydraulic fracturing from the temperature of the working oil and determination of the optimal temperature of the working oil of pumping units have not yet been carried out. The purpose of the experimental studies was to establish in laboratory and industrial conditions the relationship between the temperature of the working oil of the hydraulic system and the energy consumption of friction and the intensity of wear of the surfaces of high-pressure pumps and transmission units of mobile pumping units for hydraulic fracturing. In accordance with the formulated goal, experimental studies were carried out on the friction machine model UMT 2168 of the main patterns of change in the wear and energy characteristics of the friction surfaces of the parts of high-pressure pumps of mobile units for hydraulic fracturing FC-2251 and UN1-630×700. The results of the experiments showed that the optimal temperature regime of high-pressure pumps is from 45...65 °С. Experimental studies of the dependence of power losses in the gearboxes of mobile units for hydraulic fracturing on the temperatures of transmission oils were carried out. The results of the experiments showed that the minimum values of power losses for the automatic transmission of the FC-2251 pump unit were achieved at a transmission fluid temperature of
plus 41 °C and practically did not change with a further increase in temperature. The minimum values of power losses for the manual transmission of the UN1-630×700 pump unit were achieved at a transmission fluid temperature of plus 49 °C. It was established that the reduction in the energy consumption of friction pairs with an increase in the oil temperature to 45...65 °C is explained by a better flow of low-viscosity oil into the friction zone, better removal of wear products from the friction surfaces and more intensive heat removal. When the temperature rises above 65 °C, energy consumption begins to increase, which is associated with a violation of the hydrodynamic regime of the oil, a significant decrease in thickness and strength, as well as the subsequent destruction of the oil layer separating the friction surfaces.
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